What are the main aerosol methods for producing metal alloy powders

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Gas atomization, or gas atomization, is a method used to create metal alloy powders. Gas atomization works by breaking up the liquid metal stream with high-speed airflow into small drops and then solidifying it into powder. Powder preparation has been a major development area for special alloy and high-performance powders due to its benefits of high purity and low oxygen content. It also offers controllable particle size, low cost, and high sphericity. The following are some representative gas atomization techniques for powder production:
Laminar atomization flow technology

The German company etc. proposed the laminar atomization technique. This technology offers significant improvements over conventional nozzles. The atomizing nozzle is characterized by high atomization efficiency and narrow powder particle distribution. It also has a cooling speed between 106-107K/s. The copper, aluminum and 316L stainless-steel, etc., can be atomized under a 2.0MPa atomization force. Ar or Nitrogen is used to atomize the powder, with an average particle diameter of 10mm. It is a process that produces most metal powders and has a low gas usage. The technical control of this process is difficult. It is also unstable. And the output (metal mass flow rate less than 1kg/min), is low. This is not suitable for industrial production.

Ultrasonic tightly combined atomization technology

Close-coupled atomization using ultrasonic technology improves the design of a ring-slot nozzle to increase the flow rate and mass of metal. When atomizing high-surface energy metals like stainless steel, the average size of the particles can reach around 20mm and the standard deviation can be as little as 1.5mm.

The technology can be used to produce amorphous, fast cooling powder or powder that is cooled quickly. The current development of this equipment shows that it is the next step in the development of tightly coupled technology. It can be applied to a wide range of materials such as alloy powders and micro stainless steel.

Hot gas atomization

A US company has been conducting extensive research in recent years to determine the mechanism and effect of hot-gas atomization. In the United States, a company heated gas to 200-400degC under pressure of 1.72MPa to atomize the silver alloy and gold alloy. It found that the particle size and standard deviation decreased as the temperature increased. The hot gas atomization process is more efficient than traditional atomization, consumes less gas, and can be easily implemented on conventional atomization machines. This is a promising technology.

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